1988–1995 Kawasaki EL250 Eliminator, 250HS Service Manual (P/N 99924-1066-01)

This Kawasaki service manual set covers the EL250-B2/B3 Eliminator 250 and EL250-E1 250HS. It combines a 131-page EL250 supplement, second edition dated June 8, 1990, with the 237-page Ninja250R/GPZ250R base manual, P/N 99924-1066-01—368 PDF pages in total.

• Carburetor repair covers removal, disassembly, cleaning, inspection, synchronization, and fuel-level adjustment for the Keihin CVK units.
• Cooling-system procedures address pressure testing, radiator-cap and thermostat inspection, water-pump removal and installation, and coolant bleeding.
• Top-end work includes compression testing, cylinder-head repair, valve-clearance adjustment, valve-seat refinishing, camshaft-chain timing, and piston-ring inspection.
• Engine removal and crankcase splitting lead into crankshaft and balancer inspection, wet multi-plate clutch service, and six-speed transmission repair.
• Brake service combines front caliper and master-cylinder repair with hydraulic bleeding, plus EL250 rear-drum shoe and brake-cam inspection.
• Suspension coverage includes fork disassembly and seal replacement, twin-shock adjustment, swingarm-bearing inspection, and steering-stem service.
• Three full-vehicle wiring layouts distinguish EL250-B2/B3 Early, EL250-B3 Late, and EL250-E1, supported by component tests and individual circuit diagrams.

System Documentation and EL250 Differences

Mechanics working on the EL250 need accurate factory data to verify component wear and plan rebuilds. The supplement supplies the changes specific to these models; shared service procedures are in the included EX250-E1/E2 base manual.

That distinction matters when selecting specifications and repair procedures. The EL250 chapters address CVK30 carburetors, a rear drum brake, and twin rear shocks, rather than the CVK32 carburetors, rear disc brake, and Uni-Trak suspension described in the base manual. The 250HS has its own EL250E supplement section for further model-specific changes.

The Cooling System exploded view identifies a revised water-pump and coolant-pipe arrangement beginning with engine No. EX250EE034395. Separate California evaporative-emission coverage identifies the canister, liquid/vapor separator, and hose routing, with inspection and separator-operation checks.

Internal Engine and Driveline Repair

The crankshaft sections go beyond general wear limits. Color-coded bearing-insert selection tables relate crankpin and main-journal measurements to component identification marks, with EL-specific data for selecting replacement inserts.

Gearbox inspection covers shift forks, drum grooves, gear-dog wear, and the positive neutral finder mechanism. Exploded assembly views provide lubrication and assembly notes, while the Engine Oil Flow Chart supports the oil-pressure measurement and relief-valve inspection procedures.

The top-end cautions explain how misplaced camshaft caps can alter bearing clearance and cause camshaft seizure. Carburetor cleaning notes warn that compressed air applied to an assembled unit can damage its floats and vacuum-piston diaphragms.

Electrical Testing and Fault Tracing

Charging and ignition coverage includes alternator, regulator/rectifier, ignition-coil, and IC-igniter tests. Starter-motor inspection addresses brushes, the commutator, and the armature rather than stopping at wiring identification.

The Junction Box Internal Circuit accompanies relay, diode, and continuity checks. Early and late B3 cooling-fan circuits are distinguished, and the E1 section adds model-specific tachometer and coolant-temperature warning-system checks. A symptom-based troubleshooting guide covers starting difficulties, poor running, overheating, clutch problems, and gear-selection faults.

Essential Service Specifications and Tools

The manuals provide component-specific torque tables, fluid capacities, clearance specifications, wear limits, and electrical test values. Torque settings for key fasteners, such as cylinder head bolts and axle nuts, are provided in Newton-meters and foot-pounds.

Named workshop tools include the Fuel Level Gauge 57001-1017, Clutch Holder 57001-1243, and Coil Tester 57001-1242. These references identify the equipment called for in the fuel-system, clutch, and ignition procedures.

Included Files and Scan Limitation

Separate parts illustrations and an EL250-E wiring image accompany the two PDFs. The illustrations provide additional assembly and component references without adding to the PDF page count.

The base-manual scan is missing printed Final Drive pages 10-4 and 10-5. The EL250 supplement provides model-specific final-drive changes, not a complete replacement for those missing pages.

Proper maintenance requires adhering to the manufacturer’s limits. Use both manuals together and follow their precautions for fuel handling, brake service, and unexpected cooling-fan operation.